System and method for coiling and sealing an elongate flexible component

ABSTRACT

A system and method for coiling and sealing an elongate, flexible component includes a coiler and a sealer positioned beneath the coiler. The coiler includes a rotatable central core and a feeding tube for guiding and transferring a free end of the flexible component onto the central core to form a coil. The coil is then dropped in a generally vertical downward direction from the coiler into a partially-sealed and partially-opened container positioned beneath the coiler and disposed within the sealer. The sealer seals the remaining one or more open sides of the container and then drops the coil encased within the sealed container in a generally vertical downward direction onto a conveyor. The container may be made of a heat-shrinkable material and the conveyor may transport the sealed container into a heat-shrink oven to heat shrink the container around the coil.

CROSS REFERENCE To RELATED APPLICATION

This non-provisional patent application claims the benefit of priority of U.S. Provisional Patent Application No. 61/699,924 filed on Sep. 12, 2012.

FIELD OF THE INVENTION

The present invention relates generally to systems and methods for coiling an elongate, flexible component in the form of a coil and for subsequently sealing the coil within a protective container. More particularly, the invention is a combination coiler for winding a length of an elongate, flexible component into a coil and sealer for sealing the wound coil within a sealed container. In the exemplary embodiments herein, the invention is a combination coiler and sealer, and an associated method for coiling a length of elongate, flexible cable, wire, tubing or the like, and for subsequently encasing the wound coil within a sealed, plastic bag.

BACKGROUND OF THE INVENTION

It is common practice for lengths of an elongate, flexible component, such as cable, wire, tubing or the like to be wound into a coil. Oftentimes, the wound coil is packaged within a protective container, such as a bag or box. In certain instances, it is advantageous to encase the wound coil within a sealed, plastic bag for shipping and handling.

Coiling machines, or “coilers,” are known for winding an elongate length of a flexible cable, wire, tubing or the like into a coil. Sealing machines, or “sealers,” are separately known for sealing a wound coil of cable, wire, tubing or the like with a plastic wrap or within a sealed, plastic bag. Typically, the coiler forms the coil and the wound coil is removed from the coiler to a strapper or binder to secure the free end of the flexible component. The wound and secured coil is then moved to a sealer where the coil is first passed through a vertical sheet of plastic to wrap the coil within the plastic sheet and the plastic sheet is then sealed to encase the coil. If desired, the coil and sealed plastic sheet are then transported to an oven to shrink-wrap the plastic sheet around the coil. Coilers are also known that wind a length of an elongate, flexible component, such as cable, wire, tubing or the like, into a coil and automatically move the wound coil from the coiler into a relatively rigid container, for example an open cardboard carton.

The known coilers and sealers require a two-step coiling and sealing process, and in certain instances, require a three-step coiling, wrapping and sealing process, to coil a length of flexible cable, wire, tubing or the like and to encase the wound coil within a sealed plastic wrap or bag. Accordingly, the known systems and method for coiling and sealing require significant capital expense in multiple items of equipment and a substantial dedication of floor space. At the same time, the production rate of the known systems and methods is generally insufficient for cost efficient operations. Thus, a system and method for coiling a length of an elongate, flexible component to form a wound coil is needed that automatically moves the coil directly into a sealer to encase the coil within a sealed container. More particularly, a combination coiler and sealer is needed that forms a coil and subsequently automatically moves the wound coil into the sealer without reliance upon any mechanical means, such as moving arms, pushers or conveying devices. More particularly, a coiler for coiling a length of an elongate, flexible cable, wire, tubing or the like is needed that includes a sealer for receiving the wound coil and for encasing the coil of the elongate, flexible component in a closed container, such as a sealed, plastic bag.

SUMMARY OF THE INVENTION

The present invention is a combination coiler for coiling a length of an elongate, flexible component into a coil and sealer for encasing the coil within a sealed, plastic bag. The coiler includes a feeding tube for guiding and transferring a free end of the length of the flexible component onto a central core of the coiler. The central core is rotatable to wind the flexible component about the central core in the form of a coil having a predetermined configuration. Once the coil is formed, the opposite end of the length of the flexible component is cut adjacent the feeding tube. The central core is then opened to release the coil from the central core and the wound coil is dropped from the coiler into a partially-sealed and partially-opened bag positioned beneath the coiler and disposed within the sealer. Contemporaneously, the feeding tube is moved to the central core of the coiler and the free end of the length of the flexible component is again guided onto the central core. Any open sides of the partially-sealed and partially-opened bag disposed within the sealer are then sealed to encase the coil within a sealed, plastic bag. At the same time, the central core of the coiler is rotated to form another coil of the flexible component. The sealed plastic bag containing the previously wound coil is next released from the sealer onto a conveyor positioned beneath the sealer. The conveyor may transport the encased coil into a shrink oven for shrink-wrapping the sealed plastic bag around the coil.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an environmental elevation view of an exemplary embodiment of a combination coiler and sealer according to present invention.

FIG. 2 is a perspective view showing the sealer portion of the combination coiler and sealer of FIG. 1 in greater detail.

FIG. 2A is a sectional view of the sealer portion shown in FIG. 2 taken along the line 2A-2A.

FIG. 3 is a schematic drawing illustrating a feeding tube and a central core of the coiler portion of the combination coiler and sealer of FIG. 1 coiling a length of an elongate, flexible component into the form of a coil.

FIG. 4 is a schematic drawing illustrating the coiler portion of the combination coiler and sealer of FIG. 1 cutting the length of the flexible component from the feeding tube and opening the central core to release the coil from the central core.

FIG. 5 is a schematic drawing illustrating the coil dropping from the coiler portion of the combination coiler and sealer of FIG. 1 into a partially-sealed and partially-opened container disposed within the sealer portion, while the feeding tube of the coiler contemporaneously guides the free end of the flexible component onto the central core of the coiler.

FIG. 6 is a schematic drawing illustrating the sealer portion of the combination coiler and sealer of FIG. 1 sealing the open sides of the partially-sealed and partially-opened container, while the coiler portion coils another length of the elongate, flexible component into another coil.

FIG. 7 is a schematic drawing illustrating the sealer portion of the combination coiler and sealer of FIG. 1 releasing the coil encased within the sealed container onto a conveyor.

FIG. 8 is a schematic drawing illustrating the conveyor transporting the coil within the sealed container into a shrink oven for shrink-wrapping the sealed container around the coil.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Referring now to the accompanying drawings, in which like reference characters in the various drawing figures refer to the same or similar parts, a system for coiling a length of an elongate, flexible component into a coil and for encasing the coil within a sealed container is shown and illustrated. The system, indicated generally by reference character 10 and also referred to herein as a combination coiler and sealer 10, comprises a coiler portion, indicated generally by reference character 20 and also referred to herein as coiler 20, and a sealer portion, indicated generally by reference character 40 and also referred to herein as sealer 40. In the exemplary embodiments shown and described herein, the coiler portion 20 and the sealer portion 40 are operatively coupled together into a single, combination coiler and sealer system 10. However, as will be readily appreciated by those skilled in the art, the coiler 20 and the sealer 40 may be provided independently of one another and operatively coupled together in a coiling and sealing production environment. Regardless, the coiler 20 and the sealer 40 are configured for use with an elongate, flexible component, for example cable, wire, tubing or the like, to form a coil of the flexible component and to subsequently encase the coil within a sealed container. Those of ordinary skill in the art will readily understand and appreciate that the coiler 20 and the sealer 40 may be used in combination with one another in various other applications without departing from the otherwise broad intended scope of the invention. By way of example only and without limitation, the coiler 20 and the sealer 40 are shown and described herein configured for coiling and sealing a length of an elongate, flexible electrical cable 50 of the type commonly utilized in electrical and communications applications. As such, cable 50 comprises at least one electrical or optical conductor disposed within a protective outer sheath.

FIG. 1 shows a combination coiler and sealer 10 according to the present invention. If desired, operation of the combination coiler and sealer 10 may be controlled by an operator from a computerized controller 15 provided in conjunction with the system. As shown, the combination coiler and sealer 10 includes the coiler portion, or coiler, 20 positioned slightly vertically above the sealer portion, or sealer 40. Those of ordinary skill in the art will readily understand and appreciate that the coiler 20 may be positioned at any location relative to the sealer 40 with the addition of a means for transferring a wound coil of the elongate, flexible component from the coiler to the sealer. However, positioning the coiler 20 vertically above the sealer 40 permits a coil of the elongate, flexible component to be dropped under the influence of gravity from the coiler 20 in a generally vertical downward direction into the sealer 40. As a result, the number of individual items of equipment, the accompanying complexity and the floor space footprint of the combination coiler and sealer 10 are reduced.

In general, the coiler portion 20 of the combination coiler and sealer 10 comprises a central core 22 concentrically mounted about a shaft 24 (FIG. 3; FIG. 4). The shaft 24 and the central core 22 are driven by a conventional drive means 23 such that the central core rotates in a predetermined direction. If desired, the drive means 23 may be configured to rotate the shaft 24 and/or the central core 22 in either the counter-clockwise direction or the clockwise direction so as to produce a coil 55 of the cable 50 that unwinds in a corresponding clockwise (right-hand) direction, or conversely, in a corresponding counter-clockwise (left-hand) direction. The coiler 20 further comprises a feeding tube 26 (FIG. 3; FIG. 4) for guiding a free end 52 (FIG. 4) of the cable 50 onto the central core 22, and for transferring a length of the cable 50 onto the central core under the influence of the drive means 23 to form the coil 55. It should be noted that in certain instances it may be desirable to temporarily secure the free end 52 of the cable 50 to the central core 22 so that the cable will be transferred from the feeding tube 26 onto the central core under the influence of the drive means 23.

In general, the sealer portion 40 of the combination coiler and sealer 10 shown in greater detail in FIG. 2 and FIG. 2A comprises a roll of a sheet material 41 that is configured to be guided and delivered to the interior of the sealer 40 for sealing the wound coil of the flexible component with the plastic sheet material. As shown, the sealer portion 40 of the combination coiler and sealer 10 is movable relative to the coiler portion 20 in a generally horizontal direction indicated by the double-headed arrow 35 in FIG. 1. By way of example and not limitation, the sealer 40 may be moved horizontally relative to the coiler 20 over the floor of a manufacturing and/or production facility. In this manner, the sealer portion 40 may be moved into a position beneath the central core 22 of one or another of multiple coiler portions 20, and then subsequently moved horizontally (towards the right-hand side of the system 10 in the configuration shown in FIG. 1) so that a conveyor 60 operatively coupled with the sealer is properly positioned to transport the wound coil and sealed container from the combination coiler and sealer 10 to a heat shrink oven, as will be described hereinafter. The sealer 40 may be provided with any suitable means for moving the sealer horizontally relative to the coiler 20, including a plurality of wheels 43, as shown herein.

FIG. 3 schematically illustrates a length of the cable 50 being wound onto the central core 22 of the coiler 20 as the central core is rotated by the drive means 23 in the counter-clockwise direction indicated by arrow 25 to form a wound coil 55 of the cable. It should be noted that the coil 55 may be wound in any desired manner or pattern. By way of example only, the feeding tube 26 may be configured to traverse the longitudinal length of the central core 22 in lateral back-and-forth movements at a constant rate of travel. Alternatively, the feeding tube 26 may be configured to traverse the longitudinal length of the central core 22 in back-and-forth lateral movements at a variable rate of travel. In the latter instance, the coil 55 of the cable 50 may be formed in a non-cylindrical shape, for example in a generally spherical shape, or conversely, in an hourglass shape. In addition, the feeding tube 26 may be configured to oscillate relative to the central core 22. Alternatively, the central core may be configured to oscillate relative to the feeding tube 26. In either instance, the coil 55 of the cable 50 may be wound in a predetermined pattern, for example in a series of FIG. 8 configurations, as is well known in the art.

FIG. 4 schematically illustrates the coiler 20 cutting (i.e. severing) the cable 50 adjacent the feeding tube 26 of the coiler when the coil 55 has a predetermined configuration.

For example, the cable 50 may be cut once the coil 55 has a desired longitudinal length along the central core 22 and a desired diameter about the central core. For a given cable 50, the predetermined configuration of the coil 55 typically corresponds to a desired length of the cable delivered by the feeding tube 26 onto the central core 22 of the coiler 20. The cable 50 is cut by a conventional cutting means (not shown) in any suitable manner to produce the free end 52 of the cable adjacent the feeding tube 26 and a cut end 54 of the cable wound onto the central core 22 of the coiler 20 to form the coil 55 having the predetermined configuration with an inner diameter 56 and an outer diameter 58. The central core 22 of the coiler 20 is then opened to release the coil 55 from the central core. As used herein, the term “opened” refers generically to any operation or mechanical means that permits the coil 55 to be removed, detached, separated, or the like from the central core 22. By way of example only and without limitation, the central core 22 may be reduced in diameter concentrically and withdrawn from within the coil 55 so that the coil can be moved in a desired direction under the influence of a mechanical force, or alternatively, will drop in a downward vertical direction under the influence of gravity, as described herein.

FIG. 5 schematically illustrates the coil 55 formed from the length of wound cable 50 dropping under the influence of gravity in a generally downward vertical direction indicated by the single-headed vertical arrow 45. The coil 55 drops into the sealer portion 40 of the combination coiler and sealer 10 between a pair of sealing bars 42, 44. As shown herein, sealer 40 comprises at least a horizontal sealing bar 42 and a vertical sealing bar 44. If desired, mechanical force means may be provided for assisting the coil 55 to drop from the coiler 20 into the sealer 40 and/or to direct or guide the coil into the sealer between the sealing bars 42, 44. As shown, a partially-sealed and partially-opened container 46 formed from the roll of sheet material 41 is disposed within the sealer 40 in a position to receive the coil 55, including the cut end 54 of the cable 50. Preferably, container 46 comprises a conventional plastic bag made of a heat-sealable and heat-shrinkable material having at least two pre-sealed sides 47 so that the coil 55 of cable 50 is retained, but not yet encased and sealed within a plastic bag. As the coil 55 is dropping into the sealer 40, the central core 22 of the coiler 20 is returned to its initial unopened configuration in preparation for winding another length of the cable 50 to form another wound coil 55 in the manner previously described. At the same time, the feeding tube 26 of the coiler 20 is moved to a location adjacent the central core 22, as indicated by the curved arrow 30. As previously mentioned, the free end 52 of the cable 50 may be secured (e.g. clamped) to the central core 22 of the coiler 20 in any suitable manner.

FIG. 6 schematically illustrates the coil 55 disposed within the partially-sealed and partially-opened plastic bag 46 in the sealer 40, and the central core 22 of the coiler 20 being rotated by the drive means 23 in the counter-clockwise direction indicated by curved arrow 25. The central core 22 of the coiler 20 is rotated by the drive means 23 in the counter-clockwise direction to wind another length of the cable 50 onto the central core to form another wound coil 55. As the next coil 55 is being formed, the one or more open sides 48 remaining on the plastic bag 46 are sealed such that the coil 55, including the free end 54 of the length of the cable 50, is encased within the sealed bag. The open sides 48 of the plastic bag 46 may be sealed in any conventional and known manner, including for example without limitation, pressing and heat-sealing (e.g. thermoforming) the opposed edges of the open sides to thereby encase the coil 55 within the sealed bag.

FIG. 7 schematically illustrates the completely sealed bag 46 containing the wound coil 55 dropping in the generally vertical downward direction indicated by the arrow 65 onto a conveyor 60 having a movable conveying surface 62. As shown and described herein, the coil 55 encased within the sealed bag 46 is dropped from the sealer 40 in a generally vertical downward direction onto the conveying surface 62 of the conveyor 60 under the influence of gravity. Alternatively, the coil 55 and bag 46 may be dropped, assisted, directed and/or guided from the sealer 40 onto the conveying surface 62 under the influence of an external mechanical force in the manner previously described with reference to the coiler 20 and the sealer 40. The conveying surface 62 of the conveyor 60 is oriented at an angle relative to the vertical downward direction indicated by arrow 65, and more particularly, is inclined so that the bag 46 containing the wound coil 55 is automatically aligned parallel to the conveying surface. More specifically, the sealed bag 46 containing the coil 55 naturally tips downwardly (i.e. clockwise from the orientation shown) and over onto one side as the conveying surface 62 moves in the direction indicated by the arrow 75 in FIG. 8. If desired, the coil 55 encased within the sealed, plastic bag 46 may be moved by the conveying surface 62 of the conveyor 60 to an associated packing and shipping station to be packed into a reinforced container, for example a cardboard carton or a corrugated box, for shipment a customer or end user. Preferably, as illustrated schematically in FIG. 8, the sealed, plastic bag 46 containing the wound coil 55 is first transported into a heat shrink oven 70 operable for heat-shrinking the heat-shrinkable material of the sealed, plastic bag around the coil.

The foregoing detailed description in conjunction with the accompanying drawing figures has described one or more exemplary embodiments of a system and method for coiling a length of an elongate, flexible component in the form of a coil, and for subsequently encasing the coil within a sealed container. In an exemplary embodiment, the system and method includes a combination coiler and sealer comprising a central core, a feeding tube for guiding a length of the flexible component onto the central core, and a drive means for rotating the central core to wind the length of the flexible component onto the central core and thereby form the coil. The wound coil is then released from the central core of the coiler and received within a partially-sealed and partially-opened container positioned beneath the coiler and disposed within the sealer. The container has at least two pre-sealed sides and the sealer is configured to seal each of the remaining one or more open sides to thereby encase the coil within the fully sealed container. The elongate, flexible component is preferably selected from the group consisting of cable, wire, tubing and the like. The container is preferably a plastic bag formed from a roll of heat-sealable and heat-shrinkable sheet material. 

That which is claimed is:
 1. A system for coiling a length of an elongate, flexible component into a coil and subsequently encasing the coil within a sealed container, comprising: a coiler comprising: a rotatable central core; and a feeding tube for guiding the length of the flexible component onto the central core as the central core is rotated to thereby wind the length of the flexible component onto the central core to form the coil; and a sealer operatively coupled to the coiler to receive the coil in a partially-sealed and partially-opened container positioned beneath the coiler and disposed within the sealer, the container having at least two pre-sealed sides and one or more open sides, the sealer operable to subsequently seal the one or more open sides of the container.
 2. The system of claim 1, wherein the elongate, flexible component is selected from the group consisting of cable, wire, tubing and the like.
 3. The system of claim 1, wherein the container is made of a heat-sealable material.
 4. The system of claim 1, wherein a free end of the flexible component is secured to the central core.
 5. The system of claim 1, further comprising a drive means for rotating the central core to wind the length of the flexible component onto the central core.
 6. The system of claim 1, wherein the length of the flexible component is cut between the feeding tube and the coil when the coil has a predetermined configuration.
 7. The system of claim 6, wherein the coil is dropped from the coiler in a generally vertical downward direction under the influence of gravity and received in the container positioned beneath the coiler and disposed within the sealer.
 8. The system of claim 7, wherein the sealer comprises at least a pair of sealing bars for sealing the one or more open sides of the container to encase and seal coil in the container.
 9. The system of claim 8, wherein the coil encased and sealed in the container is dropped from the sealer in a generally vertical downward direction under the influence of gravity onto a conveying surface of a conveyor.
 10. The system of claim 9, wherein the conveying surface is inclined relative to the generally vertical downward direction so that the coil and container is automatically oriented parallel to the conveying surface when the coil encased within the container is dropped onto the conveying surface.
 11. The system of claim 10, wherein the container is made of a heat-shrinkable material and the conveyor transports the coil encased and sealed in the container to a heat shrink oven to shrink the heat-shrinkable material of the container around the coil.
 12. A combination coiler and sealer for coiling a length of an elongate, flexible component in the form of a coil, and for subsequently sealing the coil within a sealed container, the combination coiler and sealer comprising: a central core for receiving the length of flexible component thereon; a feeding tube for guiding and transferring the length of flexible component onto the central core; a partially-sealed and partially opened container having one or more open sides positioned beneath the central core for receiving the coil within the container when the coil is dropped from the central core in a generally vertical downward direction; sealing means for sealing the one or more open sides of the container so that the coil is encased and sealed in the container; and a conveyor positioned beneath the sealing means and having a conveying surface for receiving the sealed container when the sealed container is dropped in a generally vertical downward direction from the sealing means onto the conveying surface.
 13. The combination coiler and sealer of claim 12, wherein the elongate, flexible component is selected from the group consisting of cable, wire, tubing and the like, and wherein the container is a plastic bag made of a heat-sealable material.
 14. The combination coiler and sealer of claim 12, wherein the coil is dropped from the central core under the influence of gravity, and wherein the sealed container is dropped from the sealing means under the influence of gravity.
 15. The combination coiler and sealer of claim 12, wherein the conveying surface is inclined relative to the generally vertical downward direction so that the sealed container tips over under the influence of gravity and is oriented parallel to the conveying surface.
 16. The combination coiler and sealer of claim 12, wherein the container is made of a heat-shrinkable material, and wherein the conveying surface of the conveyor transports the sealed container into a heat shrink oven to shrink the heat-shrinkable material of the container around the coil.
 17. A method for coiling a length of an elongate, flexible component to form a coil, and for subsequently encasing the coil within a sealed container, the method comprising: providing a coiler comprising a rotatable central core and a feeding tube for guiding and transferring the length of the flexible component onto the central core; rotating the central core to wind the length of the flexible component onto the central core and thereby form the coil; releasing the coil from the central core of the coiler in a generally vertical downward direction; receiving the coil from the coiler in a container positioned beneath the coiler and disposed within a sealer, the container having one or more open sides; and sealing the one or more open sides of the container to thereby encase the coil within the sealed container.
 18. The method of claim 17, wherein the elongate, flexible component is selected from the group consisting of cable, wire, tubing and the like and wherein the container is made of a heat-sealable material.
 19. The method of claim 17, further comprising dropping the sealed container from the sealer in a generally vertical downward direction onto a conveying surface of a conveyor.
 20. The method of claim 19, wherein the container is made of a heat-shrinkable material, and wherein the conveying surface of the conveyor transports the sealed container into a heat shrink oven to shrink the heat-shrinkable material of the container around the coil. 